Honeycomb fired body, honeycomb filter, and method for producing honeycomb fired body

a technology of honeycomb and filter, which is applied in the direction of ceramic extrusion dies, machines/engines, chemical/physical processes, etc., can solve the problems of difficult to ensure the strength of the honeycomb fired body, damage to the environment and human body, etc., and achieve the effect of discharging ra

Active Publication Date: 2017-06-22
IBIDEN CO LTD
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0066]However, when the raw material flow suppression section is formed on the inner wall surface of the peripheral slits of the extrusion die, the raw material flow suppression section creates resistance, suppressing the discharge of the ceramic raw material from the peripheral slits. As a result, the discharge rate of the ceramic raw material to be extruded from the peripheral slits slows down, and the difference in the discharge rate between the ceramic raw material to be extruded from the peripheral slits and the ceramic raw material to be extruded from the inner slits can be reduced. This can prevent the occurrence of defects in the cell partition walls to be molded.

Problems solved by technology

Particulates (hereinafter also referred to as PM or soot) such as soot in exhaust gas emitted from internal combustion engines including diesel engines cause damage to the environment and human bodies, which has been a problem.
This makes it difficult to ensure the strength of the honeycomb fired body.

Method used

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  • Honeycomb fired body, honeycomb filter, and method for producing honeycomb fired body
  • Honeycomb fired body, honeycomb filter, and method for producing honeycomb fired body
  • Honeycomb fired body, honeycomb filter, and method for producing honeycomb fired body

Examples

Experimental program
Comparison scheme
Effect test

example 1-1

(1) Production of Honeycomb Fired Body

(1-1) Ceramic Raw Material Preparing Step

[0299]A mixture was obtained by mixing 52.8% by weight of silicon carbide coarse powder having an average particle size of 22 μm, 22.6% by weight of silicon carbide fine powder having an average particle size of 0.5 μm. To the mixture were added 4.6% by weight of an organic binder (methylcellulose), 0.8% by weight of a lubricant (UNILUB available from NOF Corporation), 1.3% by weight of glycerin, 1.9% by weight of a pore-forming agent (acrylic resin), 2.8% by weight of oleic acid, and 13.2% by weight of water. Thus, a ceramic raw material was prepared.

(1-2) Extruding Step

[0300]Next, the ceramic raw material prepared in the ceramic raw material preparing step was extruded into a honeycomb molded body as a precursor of the honeycomb fired body 10.

[0301]In the extruding step, an extrusion die having the following shape was used.

[0302]The material was cemented carbide obtained by sintering a mixture of tungst...

example 1-5

[0318]A honeycomb fired body according to Example 1-5 was produced in the same manner as in Example 1-1, except that in the extruding step (1-2), the raw material flow suppression section was provided on the inner wall surface of the outermost peripheral slit and the peripheral slits of the extrusion die. The surface roughness Ra of the provided raw material flow suppression section was 0.410 μm.

[0319]Table 1 shows the minimum thickness T1 of the inter-peripheral-cell cell partition walls and the percentage of the cross-sectional area relative to each peripheral cell to the cross-sectional area of each inner cell of the produced honeycomb fired body according to Example 1-5.

TABLE 1Cross-sectionalMinimumarea of peripheralthickness T1 (mm) ofcell / Cross-sec-Yieldinter-peripheral-celltional area ofratecell partition wallsinner cell (%)(%)Example1-10.30066.5921-20.25069.5881-30.35063.5961-40.40060.5981-50.30066.596Comparative1-10.20072.575Example

(Calculation of Yield Rate)

[0320]Fifty hon...

example 2

[0323]A honeycomb filter according to Example 2 was produced by the following method.

(1) Preparation of Honeycomb Fired Body

[0324]The honeycomb fired body according to Example 1-1 was prepared as a honeycomb fired body for a honeycomb filter.

(2) Production of Honeycomb Filter

(2-1) Adhesive Paste Preparing Step

[0325]A heat resistant adhesive paste was prepared by mixing 30% by weight of alumina fibers having an average fiber length of 20 μm, 21% by weight of silicon carbide particles having an average particle size of 0.6 μm, 15% by weight of silica sol, 5.6% by weight of carboxymethyl cellulose, and 28.4% by weight of water.

(2-2) Assembling Step

[0326]The adhesive paste was applied to the lateral sides of each prepared honeycomb fired body to assemble the honeycomb fired bodies.

[0327]Subsequently, the assembled honeycomb fired bodies were heated at 120° C., whereby the adhesive paste was solidified by heating into an adhesive layer, and an aggregate of the honeycomb fired bodies was ...

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Abstract

Provided is a honeycomb fired body in which the pressure loss in the initial state where PM has not accumulated is sufficiently low, the strength is sufficiently high, and the heat capacity is not small. The honeycomb fired body of the present invention is a honeycomb fired body including a plurality of cells in each of which one end is plugged and which serve as channels of exhaust gas, and porous cell partition walls that define the cells, wherein the honeycomb fired body is formed of SiC, the plurality of cells include peripheral cells located at an outermost peripheral region of the honeycomb fired body and inner cells located more inward than the peripheral cells, all the inner cells have the same cross-sectional shape that is a rectangle in a plane perpendicular to the longitudinal direction thereof, each peripheral cell is defined by the cell partition walls and an outer wall forming a periphery of the honeycomb fired body, the cell partition walls in contact with the outer wall each have a thick wall region where the wall thickness gradually increases toward the outer wall, the cross-sectional shape of the peripheral cells in a plane perpendicular to the longitudinal direction thereof is a shape formed by reducing the rectangular cross-sectional shape of the inner cells to obtain a reduced rectangle and chamfering or rounding two corners of the reduced rectangle, the cross-sectional area of each peripheral cell in a plane perpendicular to the longitudinal direction thereof is 60 to 80% of the cross-sectional area of each inner cell in a plane perpendicular to the longitudinal direction thereof, the cell partition walls include inter-peripheral-cell cell partition walls each located between the peripheral cells and inter-inner-cell cell partition walls each located between the inner cells, and the minimum thickness of the inter-peripheral-cell cell partition walls is greater than the thickness of the inter-inner-cell cell partition walls.

Description

TECHNICAL FIELD[0001]The present invention relates to a honeycomb fired body, a honeycomb filter, and a method for producing the honeycomb fired body.BACKGROUND ART[0002]Particulates (hereinafter also referred to as PM or soot) such as soot in exhaust gas emitted from internal combustion engines including diesel engines cause damage to the environment and human bodies, which has been a problem. Since exhaust gas contains toxic gas components such as CO, HC, and NOx, there has also been a concern for the influences of the toxic gas components on the environment and human bodies.[0003]Thus, various filters having honeycomb structures (honeycomb filters) formed of porous ceramic such as cordierite and silicon carbide have been proposed as exhaust gas purifying apparatuses. Such honeycomb filters are connected to internal combustion engines to capture PM in exhaust gas, or to purify toxic gas components such as CO, HC, and NOx in the exhaust gas.[0004]In addition, in order to improve fu...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): B01J35/04B01J27/224B28B3/20B28B3/26B01D46/24B01D53/94
CPCB01J35/04B28B2003/203B01D46/247B01D53/94B28B3/20B28B3/269B01J27/224B01D2046/2481B01D2046/2488B01D2255/1021B01D2255/1023B01D2255/1025B01D2255/2022B01D2255/2027B01D2255/2042B01D46/2474F01N3/0222F01N2330/32F01N2330/34C04B35/565C04B38/0006C04B2111/00793C04B2111/0081C04B2235/3826C04B2235/5436C04B2235/5445C04B2235/5472Y02T10/12B01D46/249B01D46/2484B01D46/2482B01D46/2478C04B38/085C04B38/0655B01D46/2462B01D46/2486
Inventor ENOSHITA, SHUNPEISHINOHARA, SATOSHI
Owner IBIDEN CO LTD
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